Composite yarn and fabric



Oct. 30, 1945. w. H. HALL, JR 2,388,140

COMPOSITE YARN AND FABRIC Filed Dec. 4, 1942 C'r/hzpea (117% [758/191- Gmu/7a 55/76 M; 779/221,;

@Mrzmwea 7(' CHM eg 725mm 2L1 5% 221;; A5277? MQM Patented Oct. 30, 1945 OOMPOSHE YARN AND FABRIC William 1!. Hall, In, Trenton, N. 1., asslgnor to Thu-mold Company, Trenton, N. 1., a corporation of New Jersey Application December 4, 1942, Serial No. 401,906

7 Claims.

This invention relates to a composite yarn for use in the ground or base structure of a textile fabric having a pile face, such as carpet, wherein the yarn which forms the pile tufts passes under predetermined warps or wefts of the ground structure and is adhesively secured thereto by a bonding substance containing rubber.

The object of the present invention is to'provide an improved yarn for either the weft or the warp, or both, of the ground structure, which will afford maximum cohesion with the bonding material and which will reduce shrinkage of the fabric to a minimum.

In the accompanying drawing:

Fig. 1 is a diagrammatic representation of a yarn made in accordance with the present invention, with the yarn drawn on an enlarged scale; and

Fig. 2 is an enlarged diagrammatic sectional view of a piece of pile fabric employing the yarn of Fig. 1 as the wefts of the ground fabric.

The improved yarn of the present invention is preferably composed, in part, of jute, and, in part, of either cotton or rayon. Preferably the jute content ranges from 50% to 70% in weight, and the cotton or rayon from 30% to 50%.

The base component, i. e. the jute, affords max imum resistance to shrinkage while the supplemental component, i. e. the cotton or rayon, affords maximum cohesion of the yarn with the bonding substance.

For the purposes of the present invention, I prefer to employ, as both the base and supplemental components, fibres of substantially equal lengths and similar characteristics insofar as the rectilinear qualities thereof are concerned, i. e. I prefer to use fibres of a maximum kinky nature.

To obtain fibres with a suitable kinky nature, I

prefer toemploy reclaimed jute, i. e. jute which has been previously used in rope, twine, burlap or other woven fabric and which has acquired a kinky nature corresponding somewhat to that of wool.

Insofar as the cotton is concerned, I prefer to employ what is commercially known and obtainable on the market as "Peruvian" cotton, due to its having the kinky characteristics best suited for the purpose.

In the case of rayon, there is a kinky variety now commercialy available on the market which serves the purpose of the present invention. In lieu of this kinky variety, reclaimed rayon which has been knitted or woven or twisted or otherwise fabricated in a manner to produce kinks in the filaments, may be employed, with the filaments cut into fibre-lengths corresponding to the fibre length of the jute employed.

The mixture of base and supplemental component fibres is worked on woolen cards, as neither the cards normally employed for regular jute or those normally employed with cotton are suited for the purpose of reducing the mixture to a suitable silver for twisting into the yarn.

Also, in the making of the yarn an ordinary wool spinning frame is employed. The mixture is not suited for working on a mule.

The completed yarn is adapted to be used in the ground structure of the carpet as the thread about which the bights of the loops of yarn which form the pile face of the fabric are bent. Preferably the yarn is used as the weft thread of a carpet having a relatively loosely woven or open base structure, with the pile loops bent around the wefts of the base fabric.

After the fabric has been woven a rubber bonding material is sprayed or spread, by doctor blade, on the back of the fabric. The bonding substance, which may be of any of the well known products used for that purpose and which are commercially available on the market, penetrates the interstices of the ground fabric and adheres to the fibres of the pile yarns and those of the ground yarns about which the bights of the pile yarns are bent, which, when the bonding material is dried or set, prevents the pile tufts from being pulled out of the ground fabric, and permits the carpet to be cut in any direction without raveling.

The carpet is primarily used in the rear of automobiles, or as door mats, etc., which are made in various shapes and sizes. No edge binding is required to keep the fabric from raveling.

By use of the improved yarn above described, a material saving in area of the fabric is made possible, due to the non-shrinking or reduced shrinking qualities of the jute component, and an improved adhesion between the pile-anchoring yarn and the pile yarn is afforded by the peculiar ailinitive characteristics of the cotton or the rayon, which characteristic is common to both these materials.

The fabric may be of any suitableweave, for example, the simple Axminster weave as commonly used in carpets employed in the automotive industry for the back passenger compartments of automobiles.

I claim:

1. A rubber integrated fabric comprising interwoven warps and wefts, at least one of which consists of a composite yarn formed of two different component kinds of fibres, including jute as reclaimed from rope, twine, burlap and the like as one of said components and a fibre having a high cohesive amnity ior rubber as the second of said components.

2. A composite yarn i'ormed of two diflerent component kinds of nbres, including crimped jute as reclaimed from rope, twine, burlap and the like as one of said components and a fibre having a high cohesive ailinity i'or rubber as the second or said components.

3. A composite yam formed 01' two diiierent component kinds of fibres, including crimped jute as reclaimed from rope, twine, burlap and the like as one of said components and a similarly kinky nbre having a high cohesive amnity for rubber as the second of said components.

4. A composite yarn formed of two diiierent kinds of fibres, including crimped jute as reclaimed from rope, twine, burlap and the like as one ofsaid components and a fibre having a high cohesive ailinity for rubber as the second of said components, said different fibres having substantially equal lengths.

5. A composite yarn composed of crimped Jute as reclaimed from rope, twine, burlap and the like and cotton.

6. A composite yarn composed of crimped jute as reclaimed from rope, twine, burlap and the like 

